8/26/2011

ResistanceWelding

ResistanceWelding

Principle
y Both heat and pressure are used.
y Heat is generated by the electrical resistance of the
work pieces and the interface between them.
y Pressure is supplied externally and is varied
throughout the weld cycle.
y Due to pressure, a lower temperature needed than
oxyfuel or arc welding.

BySKMondal

y They are not officially classified as solidstate welding

Contd

y Overall resistance very low.

y Very highcurrent (up to 100,000 A)

by the American Welding Society.

y Very lowvoltage (0.5 to 10 V) is used.

y Very rapid and economical.

y Extremely
l well
ll suited
d to automated
d manufacturing.
f
y No filler metal, no flux, no shielding gases.

Contd

Fig. The desired temperature

distribution
across
the
electrodes and the work
pieces in lap resistance
welding.

Fig.
Typical
pressure cycle
welding. The
forging and
operations.

FIG.Thefundamentalresistanceweldingcircuit

current
and
for resistance
cycle includes
post heating
Fig. The arrangement of the electrodes and the work in spot
welding, showing design for replaceable electrode tips.

8/26/2011

Advantages

Limitations

1. Very rapid.

1. High initial cost.

2. Fully automation possible.

2. Limitations to the type of joints (mostly lap joints).

3.
3 Conserve material; no filler metal,
metal shielding gases,
gases or

3 Skilled maintenance personne1 are required:

3.

flux is required.

4. special surface treatment needed.

4. Skilled operators are not required.

5.Dissimilar metals can be easily joined.
6. High reliability and High reproducibility.

Application
y The resistance welding processes are among the

most common technique for high volume

joining.

Differenttypes
1. Resistance spot welding
2. Resistance seam welding
3 Projection welding
3.
4. Upset welding
5. Flash welding
6. Percussion welding

Resistancespotwelding

HeatinputandEfficiencyCalculations

y The process description given so far is called resistance

spot welding (RSW) or simply spot welding.

y This is essentially done to join two sheetmetal jobs in

a lap
p jjoint, forming
g a small nugget
gg at the interface of
the two plates.

Contd

8/26/2011

Electric Resistance Welding

Example1
Calculate the melting efficiency in the case of arc
welding of steel with a potential of 20 V and current of
200 A. The travel speed is 5 mm/s and the cross
sectional area of the joint is 20 mm2. Heat required to
melt steel may be taken as 10 J/ and the heat transfer
efficiency as 0.85.
[PTU 2004]

Joules law applicable

Q = I2 Rt, Joules

Example2
Calculate the melting efficiency in the case of
arcwelding of steel with a potential of 20 V and
a current of 200 A. The travel speed is 5 mm/s
and .the
the cross
crosssectional
sectional area of the joint is 20
mm2. Heat required to melt steel may be taken
as 10 J/mm3 and the heat transfer efficiency as
0.85.

Example4
Two steel sheets of 1.0mm thickness are
resistance welded in a lap joint with a current of
10 000 A for 0.1 second. The effective resistance
of the joint can be taken as 100 micro ohms.
ohms The
joint can be considered as a cylinder of 5 mm
diameter and 1.5mm height. The density of steel
is 0.00786 g/mm3 and heat required for melting
steel is 10 J/mm3.

Example3
Two steel plates each 1 mm thick are spot
welded at a current of 5000 A. The current flow
time is 0.1 s. The electrodes used are 5 mm in
diameter Determine the heat generated and
diameter.
its distribution in the weld zone. The effective
resistance in the operation is 200 .

Example5
How much heat would be generated in the spot
welding of two sheets of 1 mm thick steel that
required
q
a current of 10000 A for 0.1 seconds?
An effective resistance of 100 . is assumed.

8/26/2011

Example6

Example7

Two 1.2 mm thick, flat copper sheets are being spot

welded using a current of 6000 A and a current flow
time of t = 0.18 s. The electrodes are 5 mm in diameter.
Estimate the heat generated in the weld zone. Take
effective resistance as 150 .

Two steel sheets of 1.0mm thickness are resistance

welded in a projection welding with a current of 30
000 A for 0.005 second. The effective resistance of the
joint can be taken as 100 micro ohms. The joint can be
considered
d d as a cylinder
l d off 5 mm diameter
d
and
d 1.5 mm
height. The density of steel is 0.00786 g/mm3 and heat
required for melting steel is 10 J/mm3.

Resistanceseamwelding

y Welding current is a bit higher than spot welding, to

y Weld is made between overlapping sheets of metal.

y In other process a continuous seam is produced by

compensate short circuit of the adjacent weld.

passing a continuous current through the rotating
electrodes with a speed of 1.5 m/min for thin sheet.

The seam is a series of overlapping spot welds.

y The basic equipment is the same as for spot welding.
welding

except that the electrodes are now in the form of

rotating disks.
y Timed pulses of current pass to form the overlapping

welds.
Contd

Contd

Projectionwelding
y Limitations of spot welding.
1. Electrode

condition must be maintained

continually, and only one spot weld at a time.
2. For additional strength multiple welds needed.
y Projection welding
(RPW) overcomes above
limitations.

Fig.Resistanceseamwelding

Contd

8/26/2011

y Dimples are embossed on work pieces at the weld

locations and then placed between largearea

electrodes, and pressure and current applied like spot
welding.
y Current flows through the dimples and heats them
and pressure causes the dimples to flatten and form a
weld.

y Projections are pressformed in any shape.

y Multiple welds at a time.
y No indentation mark on the surface.
y Bolts and nuts can be attached to other metal parts.

Fig.Principleof
projectionwelding,
(a)priortoapplicationof
currentandpressure
(b)andafterformationof
welds
Contd

Upsetwelding
y Made butt joint compared to lap joint.
y Pieces are held tightly and current is applied.
y Due to pressure joints get slightly upset and hence its

name.
y Useful for joining rods or similar pieces.

Contd

y This is the process used for making electric resistance

welded (ERW) pipes starting from a metal plate of suitable

thickness.
y The plate is first formed into the shape of the pipe with the
help of the three roll set as shown in Fig. above. The ends
of the p
plate would then be forming
g the butt jjoint.
y The two rotating copper disc electrodes are made to
contact the two ends of the plate through which the
current is passed. The ends get heated and then forge
welded under the pressure of the rolls.
y The ends of the pieces to be upset welded must be perfectly
parallel. Any high spots if present on the ends would get
melted first before the two ends are completely joined.

Contd

FlashWelding
y It is similar to upset welding except the arc rather than

resistance heating.
y One pieces is clamped with cam controlled movable

platen and other with is fixed platen.

Contd

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PercussionWelding

y Two pieces are brought together and the power supply is

switched on. Momentarily the two pieces are separated

to create the arc to melt the ends of the two pieces.
Then again the pieces are brought together and the
power switched off while the two ends are fused under
force. Most of the metal melted would flash out
through the joint and forms like a fin around the joint.
y Faster than upset welding.

y Similar to flash welding except arc power by a rapid

discharge of stored electrical energy.

y The arc duration is only
y 1 to 10 ms, heat is intense and

highly concentrated.
y Small weld metal is produced, little or no upsetting, and

low HAZ.
y Application: Butt welding of bar or tube where heat

damage is a major concern.

Contd

OtherWelding
h i
Technique

Thermit Welding

y Temp. 2750C produced in 30 seconds, superheating

y Heating and coalescence is by superheated molten

metal obtained from a chemical reaction between a

metal oxide and a metallic reducing
g agent.
g

the molten iron which provide both heat and filler

metal.
y Runners and risers are provided like casting.

y Used mixture one part aluminum and three parts iron

oxide and ignited by a magnesium fuse. (1150C).

y Copper, brass, and bronze can be welded using a

different starting mixture.

8Al+3Fe3O4 9Fe+4Al2O3 +heat

y Used to joint thick sections, in remote locations.

Contd

8/26/2011

ElectroSlagWelding

y A 65mm deep layer of molten slag, protect and

cleanse the molten metal.

y Very effective for welding thick sections.

y Heat is derived from the passage of electrical current

y Watercooled copper molding plates confined the

liquid and moved upward.

through a liquid slag and temp.

temp 1760
1760C
C

y Multiple electrodes are used to provide an adequate

supply of filler.

Contd

Contd

y Applications: Shipbuilding, machine manufacture,

heavy pressure vessels, and the joining of large

castings and forgings.
y Slow cooling
gp
produces a coarse g
grain structure.
y Large HAZ.

Contd

ElectronBeamWelding
y A beam of electrons is magnetically focused on the

work piece in a vacuum chamber.

y Heat of fusion is produced by electrons decelerate.
decelerate
y Allows

precise

beam

control

and

deep

weld

penetration.
y No shield gas (vacuum chamber used)

8/26/2011

LaserBeamWelding

y Very thin HAZ and little thermal distortion.

y Used a focused laser beam provides power intensities

in excess of

10kW/cm2

y Filler metal and inert gas shield may or may not used.
y Deep penetration.

y The high
highintensity
intensity beam produces a very thin column

of vaporized metal with a surrounding liquid pool.

y No
N vacuum needed.
d d
y No direct contact needed.

y Depthtowidth ratio greater than 4: 1.

Contd

ForgeWelding

y Heat input is very low, often in the range 0.1 to 10 J.

y Blacksmith do this.

y Adopted by the electronics industry.

y Possible

to weld

wires without removing

Contd

the

polyurethane insulation.
insulation

y Borax is used as a flux.

y The ends to be joined were then overlapped on the

anvil and hammered to the degree necessary to

produce an acceptable weld.
y Quality depends on the skill of the worker and not

used by industry.
Contd

FrictionWelding

y Machine is similar to a centre lathe.

y Heat is obtained by the friction between the ends of

the two parts to be joined.

y Power requirements 25 kVA to 175 kVA.

y The axial pressure depends on the strength and

hardness of the metals being joined.

y One part is rotated at a high speed and other part is

axially aligned and pressed tightly against it.

y Pressure 4
40 MPa for lowcarbon steels to as high
g as 45
450

MPa for alloy steels.

y Friction raises the temperature of both the ends. Then

rotation is stopped abruptly and the pressure is

increased to join.
Contd

Contd

8/26/2011

y Very efficient.
y Wide variety of metals or combinations of metals can

be joined such as aluminium to steel.

y Grain size is refined
y Strength is same as base metal.
metal
y Only round bars or tubes of the same size, or

connecting bars or tubes to flat surfaces can join.

y One of the components must be ductile.
y Friction welding is a solid state welding.

Contd

UltrasonicWelding(USW)

Fig frictionweldingprocess

Restricted to the lap joint

Weld thin materialssheet, foil, and wireor the

USW is a solidstate welding.

attaching thin sheets to heavier structural members.

Highfrequency (10 to 200, KHz) is applied.

Surfaces are held together under light normal

pressure.
Temp. do not exceed onehalf of the melting point.
The ultrasonic transducer is same as ultrasonic
machining.

Maximum thickness 2.5 mm for aluminum and 1.0

mm for harder metals.

Number
N b off metals
t l and
d dissimilar
di i il metal
t l combinations
bi ti
and non metals can be joined such as aluminum to
ceramics or glass.
Equipment is simple and reliable.
Less surface preparation and less energy is needed.

Contd

Applications
y Joiningthedissimilarmetalsinbimetallics
y Makingmicrocircuitelectricalcontacts.

Contd

ExplosionWelding
y Done at room temperature in air, water or vacuum.
y Surface contaminants tend to be blown off the surface.

y Weldingrefractoryorreactivemetals
ld f

y Typical impact pressures are millions of psi.

psi

y Bondingultrathinmetal.

y Well suited to metals that is prone to brittle joints

when heat welded, such as,

y Aluminum on steel
y Titanium on steel
Contd

8/26/2011

y Typically the detonation velocity should not exceed

Important factors are,

y Critical velocity
y Critical angle
y The cladding plate can be supported with tack welded
supports at the edges, or the metal inserts.

120% of the sonic velocity in the metal.

Contd

High velocity explosives, 45727620 m/s.

y TNT
y RDX
y PETN
y Composition B
y Composition C4
y Datasheet
y Primacord
Medium velocity explosives, 15244572 m/s
y Ammonium nitrate
y Ammonium perchlorate
y Amatol
y Nitroguonidine
y Dynamites
y diluted PETN

Contd

Advantages,
y Can bond many dissimilar, normally unweldable
metals
y The lack of heating preserves metal treatment
y The
Th process is
i compact, portable,
bl and
d easy to contain
i
y Inexpensive
y No need for surface preparation

Contd

Disadvantages,
y The metals must have high enough impact resistance,
and ductility (at least 5%)
y The cladding plate cannot be too large.
y Noise and blast can require worker protection,
protection vacuum
chambers, buried in sand/water.

Contd

Typicalapplications:
y Verylargeplatescanbecladded.
y Joinsdissimilarmetals.

(titaniumtosteel,Altosteel,AltoCuetc.)
y Jointubetotubesheetsoflargeheatexchangers.

Contd

Contd

10

8/26/2011

Autogeneous Welding
y Autogeneous welding or fusion of the parent

material in an inert gas shield without the use

of filler metals.

MicroPlasmaArcWeld(PAW)
y Similar to GTAW except the plasma caused by the arc

is constricted by a watercooled orifice

y Capable of high welding speeds where size permits

BrazingandSoldering
g
g

y Argon is used as the shielding gas.

BrazingandSoldering
y Brazing is the joining of metals through the use of heat

and a filler metal whose melting temperature is above

450C; but below the melting point of the metals being
joined.
Comparison with welding and the brazing process
1. The
Th composition
ii
off the
h brazing
b i
alloy
ll is
i significantly
i ifi
l
different from that of the base metal.
2. The strength of the brazing alloy is substantially lower
than that of the base metal.
3. The melting point of the brazing alloy is lower than that
of the base metal, so the base metal is not melted.
4. Capillary action or capillary attraction draws the
molten filler metal into the joint, even against the flow of
gravity.

11

8/26/2011

Brazingprocesshasseveraldistinct
advantages:

Corrosion prone

1. All metals can be joined.

2. Suited for dissimilar metals.
3. Quick and economical.
4. Less defects.

Contd

y Extremely clean surface needed.

Brazingmetalsaretypicallyalloyssuchas,

y Fluxes used are combinations of borax, boric acid,

y Brazingbrass(60%Cu,40%Zn)

chlorides, fluorides, tetraborates and other wetting

y Manganesebronze

agents.
g

y Nickelsilver
y Coppersilicon
y Silveralloys(with/withoutphosphorous)
y Copperphosphorous

Contd

Contd

y A popular composition is 75% borax and 25% boric

acid.
y Sodium cyanide is used in brazing tungsten to copper.
y Base materials not melted.
melted

12

8/26/2011

BrazeWelding

y Done with an oxyacetylene torch.

y Capillary action is not required.

y Edge preparation needed.
y Can join cast iron.
iron

Fig.BrazeWelding

Contd

Soldering
y By definition, soldering is a brazing type of operation

where the filler metal has a melting temperature

below 45
450C.
y Strength of the filler metal is low.
y Soldering is used for a neat leakproof joint or a low

resistance electrical joint.

Effective soldering generally involves six important

steps:
(1) Design of an acceptable solder joint,
(2) Selection of the correct solder for the job,
(3) Selection of the proper type of flux,
(4) Cleaning the surfaces to be joined,
(5) Application of flux, solder, and sufficient heat to
allow the molten solder to fill the joint by capillary
action and solidify, and
(6) Removal of the flux residue, if necessary.

y Not suitable for hightemp. application.

Contd

SolderMetals

SolderFlux
y Ammonium chloride or rosin for soldering tin

y Most solders are alloys of lead and tin.

y Three commonly used alloys contain 60, 50, and 40%

y Hydrochloric acid and zinc chloride for soldering

galvanized iron

tin and all melt below 240

240C
C.

y Some fluxes are corrosive and should be removed after

use

Contd

13

8/26/2011

y Silver solders uses for highertemperature service,

Electrical and Electronic purpose.

DifficultieswithGreyCastIron
Soldering and brazing are difficult of grey cast Iron due
to surface contamination with graphite having a very low
surface energy.

Weldingdesignanddefect
Welding Problem
Cracking of weld metal
Cracking of base metal
Spatter
Distortion
Slag inclusion
Porosity

LamellarTearing

Causes
High joint rigidity
Excessive stresses
Arc blow
Poor joint selection
Improper cleaning in multipass welding
Excessive H2, O2, N2, in the
welding atmosphere or Damp
electrodes
inclusionssuchasMn FeandS
inthebasemetaland/or
residualstress

Residualstress
y The residual stresses result from the restrained expansion

and contraction that occur during localized heating and

cooling in the region of weld deposit.
y The magnitude of residual stresses depends on the weldment
design support and clamping of the components being
design,
welded, their materials, welding process used, part
dimensions, welding sequence, post weld treatment, size of
the deposited weld beads, etc.
y Residual stresses should not have a harmful effect on the
strength performance of weldments, reduces fatigue
strength, May cause distortion. This residual stress may
result in the cracking of a brittle material and is not
important as far as a ductile material.

14

7/11/2011

IES2003

Resistance
Welding

Inresistancewelding,heatisgeneratedduetothe
resistancebetween
(a) Electrodeandworkpiece
(b) Asperitiesbetweentouchingplates
(c) Twodissimilarmetalsbeingincontact
(d) Interatomicforces
Ans.(b)

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MadeEasy

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IES2001

GATE2008

Themaximumheatinresistanceweldingisatthe
(a) Tipofthepositiveelectrode
(b) Tipofthenegativeelectrode
(c) Topsurfaceoftheplateatthetimeofelectric
contactwiththeelectrode
(d) InterfacebetweenthetwoplatesbeingJoined
Ans.(d)

In arc welding of a butt joint, the welding speed is

to be selected such that highest cooling rate is
achieved. Melting efficiency and heat transfer
efficiency are 0.5 and 0.7, respectively. The area of
the
h weld
ld cross section is 5 mm2 and
d the
h unit
energy required to melt the metal is 10 J/mm3. If
the welding power is 2 kW, the welding speed in
mm/s is closest to
(a) 4
(b) 14
(c) 24
(d) 34
Ans. (b)

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GATE2006
In an arc welding process, the voltage and current
are 25 V and 300 A respectively. The arc heat
transfer efficiency is 0.85 and welding speed is 8
mm/see. The net heat input (in J/mm) is
(a) 64
(b) 797
(c) 1103
(d) 79700
Ans. (b)
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GATE2007
Two metallic sheets, each of 2.0 mm thickness, are welded in a lap joint
configuration by resistance spot welding at a welding current of 10 kA and
welding time of 10 millisecond. A spherical fusion zone extending up to the full
thickness of each sheet is formed. The properties of the metallic sheets are
given as:
ambient temperature = 293 K
melting temperature = 1793 K
latent heat of fusion = 300 kJ/kg
density = 7000 kg/m3
specific heat = 800 J/kg K
Assume:
(i)
Contact resistance along sheetsheet interface is 500 microohm and along
electrodesheet interface is zero;
(ii)
No conductive heat loss through the bulk sheet materials; and
(iii) The complete weld fusion zone is at the melting temperature.
The melting efficiency (in %) of the process is
(a)
50.37
(b)
60.37
(c)
70.37
(d)
80.37
Ans. (c)
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7/11/2011

GATE2005
Spot welding of two 1 mm thick sheets of steel
(density = 8000 kg/m3) is carried out successfully
by passing a certain amount of current for 0.1
second through the electrodes. The resultant weld
nugget formed
f
d is 5 mm in diameter
d
and
d 1.5 mm
thick. If the latent heat of fusion of steel is 1400
kJ/kg and the effective resistance in the welding
operation in 200 , the current passing through the
electrodes is approximately
(a) 1480A
(b) 3300 A
(c) 4060 A
(d) 9400 A
Ans. (c)
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GATE2001
Resistance spot welding is performed on two
plates of 1.5 mm thickness with 6 mm diameter
electrode, using 15000 A current for a time
duration of 0.25 seconds. Assuming the interface
resistance to be
b 0.0001 , the
h heat
h
generated
d to
form the weld is
(a) 5625 Wsec
(b) 8437 Wsec
(c) 22500 Wsec
(d) 33750 Wsec
Ans. (a)
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GATE2004

GATE1992

Two 1 mm thick steel sheets are to be spot welded

at a current of 5000 A. Assuming effective
resistance to be 200 microohms and current flow
time of 0.2 second, heat generated during the
process will
ll be
b
(a) 0.2 Joule (b) 1 Joule
(c) 5 Joule
(d) 1000 Joules
Ans. (d)

For resistance spot welding of 1.5 mm thick steel

sheets, the current required is of the order of
(a) 10 A
(b) 100 A
(c) 1000 A
(d) 10,000 A
Ans. (d)

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GATE2010

IAS2003

Two pipes of inner diameter 100 mm and outer

diameter 110 mm each joined by flash butt
welding using 30 V power supply. At the interface,
1 mm of material melts from each pipe which has
a resistance of 42.4 . If the unit melt energy is
64.4 MJm3, then time required for welding in
seconds is
(a) 1
(b) 5
(c) 10
(d) 20
Ans. (c)

Assertion (A): Spot welding is adopted to weld two

overlapped metal pieces between two electrode points.
Reason (R): In this process when current is switched on,
the lapped pieces of metal are heated in a restricted area.
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
Ans. (a)

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7/11/2011

Example1
Calculate the melting efficiency in the case of arc
welding of steel with a potential of 20 V and current of
200 A. The travel speed is 5 mm/s and the cross
sectional area of the joint is 20 mm2. Heat required to
melt steel may be taken as 10 J/ and the heat transfer
efficiency as 0.85.
[PTU 2004]

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Example3
Two steel plates each 1 mm thick are spot
welded at a current of 5000 A. The current flow
time is 0.1 s. The electrodes used are 5 mm in
diameter.
diameter Determine the heat generated and
its distribution in the weld zone. The effective
resistance in the operation is 200 .

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Example5
How much heat would be generated in the spot
welding of two sheets of 1 mm thick steel that
required
q
a current of 10000 A for 0.1 seconds?
An effective resistance of 100 . is assumed.

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Example2
Calculate the melting efficiency in the case of
arcwelding of steel with a potential of 20 V and
a current of 200 A. The travel speed is 5 mm/s
and .the
the cross
crosssectional
sectional area of the joint is 20
mm2. Heat required to melt steel may be taken
as 10 J/mm3 and the heat transfer efficiency as
0.85.

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Example4
Two steel sheets of 1.0mm thickness are
resistance welded in a lap joint with a current of
10 000 A for 0.1 second. The effective resistance
of the joint can be taken as 100 micro ohms.
ohms The
joint can be considered as a cylinder of 5 mm
diameter and 1.5mm height. The density of steel
is 0.00786 g/mm3 and heat required for melting
steel is 10 J/mm3.

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Example6
Two 1.2 mm thick, flat copper sheets are being spot
welded using a current of 6000 A and a current flow
time of t = 0.18 s. The electrodes are 5 mm in diameter.
Estimate the heat generated in the weld zone. Take
effective resistance as 150 .

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7/11/2011

Example7
Two steel sheets of 1.0mm thickness are resistance
welded in a projection welding with a current of 30
000 A for 0.005 second. The effective resistance of the
joint can be taken as 100 micro ohms. The joint can be
considered
d d as a cylinder
l d off 5 mm diameter
d
and
d 1.5 mm
height. The density of steel is 0.00786 g/mm3 and heat
required for melting steel is 10 J/mm3.

OtherWelding
Technique
h i

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IES2000
Considerthefollowingprocesses:
1. Gaswelding
2. Thermit welding
33. Arcwelding
g
4. Resistancewelding
Thecorrectsequenceoftheseprocessesinincreasing
orderoftheirweldingtemperaturesis
(a) 1,3,4,2
(b) 1,2,3,4
(c) 4,3,1,2
(d)4,1,3,2
Ans.(d)
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IAS2003
Whichoneofthefollowingisnotanelectric
resistancemethodofwelding?
(a) Electroslagwelding
(b) Percussionwelding
(c) Seamwelding
(d) Flashwelding
Ans.(a)

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IAS2000

IES2004

Considerthefollowingweldingprocesses:
1. TIGwelding
2. Submergedarcwelding
3. Electroslagwelding4. Thermit welding
Whichoftheseweldingprocessesareusedforwelding
Whi h fth ldi
df ldi
thickpiecesofmetals?
(a) 1,2and3 (b) 1,2and4
(c) 1,3and4 (d) 2,3and4
Ans.(d)

Assertion (A): In electron beam welding process,

vacuum is an essential process parameter
Reason (R): Vacuum provides a highly efficient
shield on weld zone
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
Ans. (d)

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IES2002
Inwhichoneofthefollowingweldingtechniques
isvacuumenvironmentrequired?
(a) Ultrasonicwelding
(b) Laserbeamwelding
(c) Plasmaarcwelding
(d) Electronbeamwelding

IES1993
Electronbeamweldingcanbecarriedoutin
(a) Openair
(b) Ashieldinggasenvironment
(c)
( ) Apressurizedinertgaschamber
A
i di t h b
(d) Vacuum
Ans.(d)

Ans.(d)

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IAS2004
Whichoneofthefollowingweldingprocesses
consistsofsmallerHeatAffectedZone(HAZ)?
(a) Arcwelding
(b) Electronbeamwelding
(c) MIGwelding
(d) Thermit welding
Ans.(b)

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IES2007
Considerthefollowingstatementsinrespectofthe
laserbeamwelding:
1. Itcanbeusedforweldinganymetalortheir
combinationsbecauseofveryhightemperatureofthe
focalpoints.
focalpoints
2. Heataffectedzoneisverylargebecauseofquick
heating.
3. Highvacuumisrequiredtocarrytheprocess.
Whichofthestatementsgivenaboveis/arecorrect?
(a) 1and2only (b) 2and3only
(c) 1only
(d) 1,2and3
Ans.(c)
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IES2006

IAS2007

Whichoneofthefollowingweldingprocesses
consistsofminimumheataffectedzone(HAZ)?
(a) ShieldedMetalArcWelding(SMAW)
(b) LaserBeamWelding(LBW)
(c) UltrasonicWelding(USW)
(d) MetalInertGasWelding(MIG)

Consider the following welding processes:

1. Arc welding
2.
MIG welding
3. Laser beam welding
4.
Submerged arc
welding
Select the correct sequence in increasing order of Heat
affected zone (HAZ) using the code
given below:
(a) 1 2 3 4 (b) 1 4 2 3
(c) 3 2 4 1 (d) 4 3 2 1
Ans. (c)

Ans.(b)

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IAS1999

GATE2007

Match List I (Shielding method) with List II (Welding

process) and select the correct answer using the codes
given below the lists:
List I
List II
A. Flux coating
1.
Gas metal arc welding
B.
Flux
2.
Submerged
B
Fl granules
l
S b
d arc welding
ldi
C. CO2
3.
Shielded metal arc welding
D. Vacuum
4.
Laser beam welding
5.
Electron beam welding
Codes:A B
C
D
A
B
C
D
(a) 1
2
5
3
(b)
1
4
2
5
(c) 3
5
1
4
(d)
3
2
1
5
Ans. (d)

Whichoneofthefollowingisasolidstatejoining
process?
(a) Gastungstenarcwelding
(b) Resistancespotwelding
(c) Frictionwelding
(d) submergedarcwelding
Ans.(c)

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IES2011S1Contd
MatchListIwithListIIandselectthecorrectanswer
usingthecodegivenbelowthelists:

GATE1992
Inanexplosiveweldingprocess,the..
(maximum/minimum)velocityofimpactisfixed
bythevelocityofsoundinthe
(flyer/target)platematerial
(a) Maximum;target
(b) Minimum;target
(c) Maximum;flyer
(d) Minimum;flyer

ListI

B.Electron
2.Asoundandcleanweldedjointiscreateddueto
beamwelding rubbingoftwopartsagainsteachotherwith
adequatespeedandpressureproducingintenseheat
raisingtemperatureabovemeltingpoint.
C.Ultrasonic 3.Cleanheatsourcecreatedmuchawayfromjob,a
welding
narrowspotisheated,workchamberoperatesina
highvacuum.
D.Friction
welding

Ans.(c)

ListII

A.Laserbeam 1.Canbeappliedforweldingorrefractorymetals
welding
likeniobium,tantalum,molybdenumandtungsten.

4.Cleanheatsourceveryquickheating,verysmall
focalspot,novacuumchamberisrequired.

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IES2011FromS1
Codes:
A
(a) 4
((c)) 4
Ans.(a)

B
3
1

C
1
3

D
2
4

(b)
((d))

A
2
2

B
3
1

IES2009
C
1
3

D
4
4

MatchListIwithListIIandselectthecorrectanswerusingthecodegiven
belowtheLists:
ListI
ListII
(WeldingProcess)
(Application)
A. Laserwelding
1.
Unitinglargeareasheets
B. Frictionwelding
2.
Repairinglargeparts
C.
3.
Weldingarodtoaflatsurface
C Ultrasonicwelding
3
D. Explosivewelding
4.
Fabricationofnuclearreactor
components
5.
Weldingverythinmaterials
Code:
(a)
A
B
C
D
(b)
A
B
C
D
5
4
3
2
1
4
2
5
(c)

A
1

B
3

C
4

D
2

(d)

A
5

B
3

C
4

D
1

Ans.(d)
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7/11/2011

IAS2002

IAS2001

MatchListI,(Welding)withListII(Application)andselectthecorrect
answerusingthecodesgivenbelowtheLists:
ListI
ListII
(Welding)
(Application)
A.
Explosive
1.
Joiningthicksheets
g
B.
Ultrasonic
2.
Manufactureofheatexchanges
C.
Thermit
3.
Joiningthinsheetsorwiresof
similar/dissimilar metals
D.
Projection
4.
Joininghydraulicpistonrodsfor
agricultural machinery
5.
Joiningrails,pipesandthicksteel
sections
Codes:A
B
C
D
A
B
C
D
(a) 2
5
1
3
(b)
4
5
1
3
(c) 2
3
5
1
(d)
4
3
5
1
Ans.(c)

MatchListI(Weldingprocesses)withListII(Features)and
selectthecorrectanswerusingthecodesgivenbelowtheLists:
ListI
A. Ultrasonicwelding

1.

B.

Electronbeamwelding2.

C.

Plasmaarcwelding

Codes:
(a)
(c)
Ans.(d)

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A
1
2

B
2
1

3.
4.
C
4
4

ListII
Gasheatedtoionizedcondition
forconductionofelectriccurrent
Highfrequencyandhigh
intensityvibrations
Concentratedstreamofhigh
energyelectrons
Exothermalchemicalreaction
A
B
C
(b)
4
3
1
(d)
2
3
1

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JWM2010
MatchListIwithListIIandselectthecorrectanswer
usingthecodegivenbelowthelists:
ListI
ListII
A.Atomic
1.Twopiecesarebroughttogetherand
hydrogenwelding powersupplyisswitchedon
B.Plasmaarc
B Plasma arc
welding
C.Spotwelding

2.Nuggetisformedattheinterfaceof
2 Nuggetisformedattheinterfaceof
twoplates
3.Gasisionized

D.Flashwelding

4.Inertgasshieldedarcwelding

Code:A
(a) 4
(c) 4

B
3
2

C
D
A
2
1
(b) 1
3
1
(d) 1
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B
3
2

C
2
3

BrazingandSoldering
g
g
D
4
4

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IES2006

GATE2005
Thestrengthofabrazedjoint
(a) Decreaseswithincreaseingapbetweenthetwo
joiningsurfaces
(b) Increaseswithincreaseingapbetweenthetwo
joiningsurfaces
j i i f
(c) Decreasesuptocertaingapbetweenthetwo
joiningsurfacesbeyondwhichitincreases
(d) Increasesuptocertaingapbetweenthetwo
joiningsurfacesbeyondwhichitdecreases
Ans.(d)
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Whichoneofthefollowingisnotafusionwelding
process?
(a) Gaswelding
(b) Arcwelding
(c) Brazing
(d) Resistancewelding
Ans.(c)

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IES1994

IAS1996

MatchList IwithList IIandselectthecorrectanswer

usingthecodesgivenbelowtheLists:
List I(Filler)
List II(Joiningprocess)
A. Cu,Zn,Agalloy
1.
Brazewelding.
B. Cu,Sn,alloy
2.
Brazing
C. Pb,Sb,alloy
3.
Soldering
D.Iron oxideandaluminium powder4. TIGweldingof
aluminium
Codes:A B
C
D
A
B
C
D
(a) 2
1
3

(b) 1
2
4

(c) 2
1
3
4
(d) 2

3
4

MatchListIwithListIIandselectthecorrectanswerusing
thecodesgivenbelowthelists
ListI
ListII
(Fillerrodmaterial)
(Joiningprocess)
A. Mildsteel
1.
MIGwelding
B. Bronze
2.
Soldering
C. Brass
3.
Brazing
D. Leadandtinalloy 4.
Thermit welding
5.
Brazewelding
Codes:A
B
C
D
A
B
C
D
(a) 1
5
3
2
(b)
4
3
2
5
(c) 4
3
5
2
(d) 1
3
5
4
Ans.(a)

Ans.(a)
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IES2004
MatchListI(Weldingproblems)withListII(Causes)andselect
thecorrectanswerusingthecodesgivenbelowtheLists:
ListI
ListII
A. Crackingofweldmetal
1.
Excessivestresses
B. Crackingofbasemetal
2.
Highjointrigidity
C.
C
Porosity
3.
3
Failuretoremoveslag
frompreviousdeposit
D. Inclusions
4.
Oxidation
5.
ExcessiveH2,O2,N2,in
theweldingatmosphere
Codes:A
B
C
D
A
B
C
D
(a) 2
1
5
3
(b)
3
4
2
1
(c) 2
4
5
3
(d)
3
1
4
2
Ans.(a)

IES2003
MatchListI(WeldingDefects)withListII(Causes)and
selectthecorrectanswerusingthecodesgivenbelowthe
Lists:
ListI
ListII
(WeldingDefects)
(Causes)
A Spatter
A.
S
1.
D
Dampelectrodes
l
d
B. Distortion
2.
Arcblow
C. Slaginclusion
3.
Impropercleaningin
multipasswelding
D. Porosity
4.
Poorjointselection
Codes:A B
C
D
A
B
C
D
(a) 4
2
3
1
(b) 4
2
1
3
(c) 2
4
1
3
(d) 2
4
3
1
Ans.(d)

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IES2004
Consider the following statements:
The magnitude of residual stresses in welding
depends upon
1. Designofweldment
2. Supportandclampingofcomponents
S
d l
f
3. weldingprocessused
4. Amountofmetalmelted/deposited
Whichofthestatementsgivenabovearecorrect?
(a) 1,2and4
(b)1,2and3
(c) 1and3
(d)2and3
Ans.(b)
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GATE2003
Matchthefollowing
Workmaterial
P.Aluminium
Q.DieSteel
R.CopperWire
S.Titaniumsheet

(a)P 2
(b)P 6
(c)P 4
(d)P 5
Ans.(d)

Q 5
Q 3
Q 1
Q 4

R 1
R 4
R 6
R 2

Typeofjoining
1.
SubmergedArcWelding
2.
Soldering
3.
Thermit Welding
4.
AtomicHydrogenWelding
5.
GasTungstenArcWelding
6.
LaserBeamWelding
7.
Brazing
S 3
S 4
S 2
S 6

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IES2004
Considerthefollowingstatements:
Thesizeoftheheataffectedzone(HAZ)willincreasewith
1. Increasedstartingtemperature
2. Increasedweldingspeed
3. Increasedthermalconductivityofthebasemetal
4. Increaseinbasemetalthickness
Whichofthestatementsgivenabovearecorrect?
(a) 1,2and3
(b) 1and3
(c) 1and4
(d) 2and3
Ans.(b)

IES1992
Weldspatteroccursduetoanyofthefollowing
except
(a) Highweldingcurrent
(b) Toosmallanelectrode
(c) Arc
(d) Wrongpolarity
Ans.(d)

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JWM2010
Assertion (A) : Spatter is one of the welding defects.
Reason (R) : In submerged arc welding process,
there is no spatter of molten metal.
(a) Both A and R are individually true and R is the
correct explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
Ans. (b)

IES1998
Anarcweldedjointisshownintheabovefigure.
Thepartlabelled 'B'inthefigureisknownas
(a) Weldpreparation
(b) Penetration
(c) Reinforcement
(d) Slag

Ans.(c)

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IES2004

IAS2003

Assertion (A): A sound welded joint should not only

be strong enough but should also exhibits a good
amount of ductility
Reason (R): Welding process is used for fabricating
mild steel components only
(a) Both A and R are individually true and R is the correct
explanation of A
(b) Both A and R are individually true but R is not the
correct explanation of A
(c) A is true but R is false
(d) A is false but R is true
Ans. (c)

Toolmaterialnotsuitedtoresistanceweldingis
(a) Aluminium oxide
(b) Stellite
(c) Highspeedsteel
(d) Masonite

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Ans.(a)

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GATE1996
Preheatingbeforeweldingisdoneto
(a) Makethesteelsofter
(b) Bumawayoil,grease,etc,fromtheplatesurface
(c) Preventcoldcracks
(d) Preventplatedistortion
Ans.(c)

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IES2011

Coldcrackinginsteelweldments dependson
1.Carbonequivalent
2.Heatinput
3.Effectivethickness
3.Hydrogencontentinweldpool
H d

i ld
l
(a)1,2and3only
(b)1,2and4only
(c)2,3and4only
(d)1,2,3and4
Ans.(d)
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GATE2001
Two plates of the same metal having equal
thickness are to be butt welded with electric arc.
When the plate thickness changes, welding is
achieved by
(a) Adjusting the current
(b) Adjusting the duration of current
(c) Changing the electrode size
(d) Changing the electrode coating
Ans. (a)
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